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Factory Service Manual
Instructions from Unorthodox Racing Pulley Kit
Unorthodox Racing Lightweight Pulley Kit Installation
(by Zippysedan, instructions with the kit plus a few pearls)
Disclaimer: edit: automatic transmission (like mine) = huge pain in the ass, pay someone $200. You need to drain ALL the fluids and disconnect stuff from the radiator area to get the fan out of the way, otherwise getting at things is incredibly awkward. Don't work on your car if it's not a good idea. Some people should not work on cars, if you're one of them, don't. For instance, I drive a G35 sedan (A/T) and I could not see a way to drop the fan assembly without draining the radiator, something I was not prepared for. I will be bringing it to a shop tomorrow, because draining the oil (removal of the oil filter will drain enough to matter) and draining the coolant were more than I bargained for.
- If you're using ramps to get the car up in the air, position it now, you won't want to run it after
- Open hood (it really says this, even tels you why) and remove engine cover
- Remove air box/filter assembly, also free the overflow hose from the fan/shroud assembly and disconnect the battery. (DO NOT REMOVE THE OVERFLOW HOSE, JUST FREE IT UP FROM THE FAN ASSEMBLY)
- If you're using a lift or a jack and stands, now's the time. Put it in park. I like using the E brake too.
- Remove lower engine cover, then 2 bolts holding fan assembly, then lower fan assembly.
- Loosen water pump pulley nuts but do not fully unthread them. (No, unthread is not a word, but remove is)
- Dismount alternator, removal of oil filter is recommended for alternator pulley nut removal. Dismounting is done by undoing the lower bolt first then the upper bolt, making sure the fan assembly is low enough to remove the long bolt. This procedure allows for easy access to alternator nut pulley via impact gun.
- Loosen the crankshaft pulley but do not remove yet.
- Manual Transmission: Have helper put car in 6th gear and hold brake firmly, the nut is very tight and will require significant force to loosen. A 3/4" impact gun is the easiest method of removal.
- Automatic transmission: Follow the crank pulley removal procedure/s specified in the factory manual.
- Loosen the accessory drive belts and remove the stock crank pulley and accessory pulleys.
- The crank pulley comes with a 1MM thick steel sleeve pressed over the outer diameter of the hub on the rear of the pulley, the side of the pulley with the part numbers, where the pulley fits into the engine oil seal. For visual reference the sleeve has a slight taper at the end. The front oil seal rides against the sleeve sealing the crankcase. As a precaution, check to insure the pulley has the sleeve pre-installed. Do not install if sleeve is not present, as a major oil leak or severe engine damage could occur. This is in bold on the UR instructions, so they must really mean it.
- Install underdrive crankshaft pulley; lightly coat the inner bore of the new pulley with anti-seize compound and tighten the crankshaft pulley bolt, Make sure the crank shout edge has no burrs, if there are no burrs the pulley will slip on easily and seat properly. Do not force the pulley onto the crankshaft, or you will cause damage to both that will void the warranties. In rare cases when it's tight, probably from rust, clean it with emery cloth until it slides on. It also says see torque specification below (Why put it below? I don't get it, they should just put it here. Well then I will, it's 29-36 ft/lbs (348-432 in/lbs or 39-49 N/M), but then you have tighten it another 60 degrees. The best way to do that is use one of the marks on the crankshaft pulley bolt as a reference. You need to make a mark on the crankshaft next to one of the 6 radial marks on that bolt, then turn it to the next mark.
- Install the new alternator and water pump pulleys; lightly coat the inner bore of the new pulleys and the rear surface of the water pump pulley that contacts the steel mounting flange with anti-seize compound.
- Install the new accessory belts in reverse order (Gates brand belts recommended, use 45 1/4 in or 1150mm for the alternator, power steering, and water pump belt, and a 35 7/8 or 910mm AC belt.
